Systems and methods for intelligent charging and intelligent conditioning of a high voltage battery

ABSTRACT

The technology described herein provides a stand-alone intelligent battery charger and intelligent conditioner for use with a high-voltage battery, such as those used in hybrid automotive vehicles. Additionally, in various exemplary embodiments, this technology provides a system and method for validating the capacity of a high voltage battery. Other comparable uses are also contemplated herein, as will be obvious to those of ordinary skill in the art.

FIELD OF THE INVENTION

The technology described herein relates generally to high voltagebatteries, such as, for example, those that are used, in hybridautomotive vehicles. More specifically, the technology described hereinrelates to a portable, stand-alone system and associated method for theintelligent charging and intelligent conditioning of a high voltagebattery. Furthermore, the technology described herein relates to asystem and method for validating the capacity of a high voltage battery.Other comparable uses are also contemplated herein, as will be obviousto those of ordinary skill in the art.

BACKGROUND OF THE INVENTION

Rechargeable energy storage devices are utilized in hybrid vehicles thatare powered by both petroleum-based and electrical-based propulsionsystems. These rechargeable energy storage devices include high voltagebatteries. When, a high voltage battery is unable to provide sufficientpower to start a vehicle, an intelligent charger is utilized to rechargethe battery. A technician is often required to determine the health ofthe battery. This includes determining not only the capacity of thebattery pack, but also the cell\module voltage differentials.

When the need, arises to recharge such a high voltage battery, the knownsystems and methods are cumbersome. Known systems are limited in theirintelligent electronic monitoring, thus increasing safety risks to auser of such a system. Often such systems are bulky and heavy, thus notportable and mobile. Additionally, known systems require the use andintegration of some interface device, such as a laptop computer duringthe intelligent battery charging and conditioning. Furthermore, knownsystems require special controller area network (CAN) communicationsoftware during the intelligent battery charging and conditioningprocesses. Usually a laptop, or like device, and a power supply isrequired in which the power supply is set at a peak voltage well belowthe peak voltage of the battery pack. This process is known as floating.Therefore, a need still exists in the art for such a system and methodas the one described herein.

BRIEF SUMMARY OF THE INVENTION

In various exemplary embodiments, the technology described hereinprovides a portable, stand-alone intelligent battery charger andintelligent conditioner for use with a high-voltage battery, such asthose used in hybrid automotive vehicles. Additionally, in variousexemplary embodiments, this technology provides a system and method forvalidating the capacity of a high voltage, battery. Other comparableuses are also contemplated herein, as will be obvious to those ofordinary skill in the art.

In one exemplary embodiment, the technology provides a system for theintelligent charging and conditioning of a high voltage propulsionbattery to a desired state of charge. The system includes a high voltagesource, a battery conditioner, the battery conditioner being powered bythe high voltage source and being configured to electrically attach, toa high voltage battery and assess a plurality of battery diagnostics, acontrol interface, the control interface being powered by the highvoltage source, a low voltage source, the low voltage source beinglocated within the control interface and providing power to a batteryconditioner control and a data logging device, and a power supply anddischarge unit, the power supply and discharge unit being located withinthe battery conditioner and being configured to discharge and charge ahigh voltage battery to a desired state of charge. The batteryconditioner, the control interface, the low voltage source, the datalogging device, and the power supply and discharge unit comprise aportable, stand-alone system. The data logging device records highvoltage battery data prior, during, and after battery conditioning forengineering analysis and prints a paper receipt of logged activities.The data also is stored for later analysis. For example, the data islater extracted via a connected laptop.

The system is coupled, to a high voltage battery to charge the highvoltage battery to a desired state of charge. Optionally, the system iscoupled to a high voltage battery, the battery being located in a hybridor electric vehicle, to charge the high voltage battery to a desiredstate of charge and start the vehicle. The system, however, is notlimited to the situation where a battery is unable to start a vehicle.

The system further includes a user interface, the user interfaceincluding a display screen and being configured to provide a user withbattery diagnostic data, battery conditioner data, and state of chargedata. The data is displayed to the user prior, during, and after batteryconditioning. Optionally, the user interface further includes an audiblewarning system, wherein the audible warning system informs a user of acritical battery status.

The system further includes updatable logic configured to auto-recognizea high voltage battery, safeguard against exceeding limitations of thehigh voltage battery, and use controller area network (CAN) parametersand/or diagnostic parameters for battery conditioning algorithms. Theupdatable logic is further configured to charge a high voltage batteryto a predetermined nominal state of charge. The updatable logic isfurther configured to charge a high voltage battery to a predeterminedexact state of charge. Thus, the system is used to achieve either anominal state of charge or an exact state of charge, in this embodiment.

In another exemplary embodiment, the technology provides a method forthe intelligent charging and conditioning of a high voltage propulsionbattery to a desired state of charge. The method includes utilizing ahigh voltage load source\charge unit, attaching a battery conditioner toa high voltage battery; the battery conditioner being powered by thehigh voltage source and being configured to electrically attach to ahigh voltage battery and assess a plurality of battery diagnostics,utilizing a control interface; the control interface being powered bythe high voltage source, utilizing a low voltage source; the low voltagesource being located within the control interface and providing power toa battery conditioner control and a data logging device (the controlarchitecture for the battery), utilizing a power supply and dischargeunit, the power supply and discharge unit being located within thebattery conditioner and being configured to discharge and charge a highvoltage battery to a desired state of charge, displaying a plurality ofinternal diagnostics of the high voltage battery, and determiningwhether a user desires a quick charge of the high voltage battery.

In one exemplary embodiment, the method further includes selecting aquick charge of the high voltage battery, determining a target state ofcharge, charging or discharging the high voltage battery until thetarget state of charge has been reached, checking, with the batteryconditioner, for a rational relationship between the target state ofcharge and a battery management system located within the high voltagebattery, and displaying the battery conditioner's cycle data.

In another exemplary embodiment, the method further includes, selectingwhether to seek a target state of charge to cycle the high voltagebattery, upon selecting to seek a target state of charge, determining,by the battery conditioner, the target state of charge, selectingwhether the state of charge desired is to be nominal or exact, uponselecting an exact state of charge, discharging the high voltage batteryto a lower voltage threshold, charging the high voltage battery to anupper voltage threshold, discharging the high voltage battery to thetarget state of charge determined by the battery conditioner, checking,with the battery conditioner, for a rational relationship between thetarget state of charge and a battery management system located withinthe high voltage battery, and displaying the battery conditioner's cycledata.

In yet another exemplary embodiment the method further includesselecting whether to seek a target state of charge to cycle the highvoltage battery, upon selecting to seek a target state of charge,determining, by the battery conditioner, the target state of charge,selecting whether the state of charge desired is to be nominal or exact,upon selecting a nominal state of charge, discharging the high voltagebattery cell\module or pack to a lower voltage threshold, charging thehigh voltage battery to a state of charge as indicated by a batterymanagement system located within the high voltage battery, checking,with the battery conditioner, for a rational relationship between thetarget state of charge and the battery management system located withinthe high voltage battery, and displaying the battery conditioner's cycledata.

In yet another exemplary embodiment, the method further includesselecting whether to seek a target, state of charge to cycle the highvoltage battery, upon selecting to cycle the high voltage battery,discharging the high voltage battery to a lower voltage threshold,discharging the high voltage battery to a lower voltage threshold,charging the high voltage battery to an upper voltage threshold,repeating the discharging and charging processes, discharging, the highvoltage battery to a target state of charge determined by the batteryconditioner, checking, with the battery conditioner, for a rationalrelationship between the target state of charge and the batterymanagement system located within the high voltage battery, anddisplaying the battery conditioner's cycle data.

In still yet another exemplary embodiment, the method further includesutilizing updatable logic configured to auto-recognize a high voltagebattery, safeguard against exceeding limitations of the high voltagebattery, and use controller area network (CAN) parameters and/ordiagnostic parameters for battery conditioning algorithms.

In still yet another exemplary embodiment, the method further includesutilizing a user interface, the user interface comprising a displayscreen and being configured to provide a user with battery diagnosticdata, battery conditioner data, and state of charge data, and whereinthe data is displayed to the user prior, during, and after batteryconditioning. Optionally, the user interface further includes an audiblewarning system, wherein the audible warning system informs a user of acritical battery status.

In still yet another exemplary embodiment, the method further includesrecording, by the data logging device, high voltage battery data prior,during, and after battery conditioning for engineering analysis, andprinting a paper receipt of logged activities.

In still yet another exemplary embodiment, wherein the high voltagebattery is a propulsion battery in a hybrid or electric vehicle, andwherein the battery conditioner, the control interface, the low voltagesource, the data logging device, and the power supply and discharge unitcomprise a portable, stand-alone unit, the method further includescoupling the battery conditioner and the power supply and discharge unitto the high voltage battery within the vehicle, charging the highvoltage battery to a state of charge such that the vehicle is capable ofbeing started, decoupling the battery conditioner and the power supplyand discharge unit from the high voltage battery within the vehicle, andstarting the vehicle.

Advantageously, the stand-alone battery charger and conditioner providesbetter portability and mobility over known systems in the art.Additionally, the stand-alone battery charger and conditioner providesincreased safety to a user with the automatic shut-off of intelligentcharging and conditioning once defined exit conditions are met.Furthermore, the stand-alone battery charger and conditioner providesfor the automatic adaptation to various types and/or manufacturers ofhigh voltage battery packs.

There has thus been outlined, rather broadly, the features of thetechnology in order that the detailed description that follows may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are additional features of thetechnology that will be described and which will form the subject matterof the claims. Additional aspects and advantages of the technology willbe apparent from the following detailed description of an exemplaryembodiment which is illustrated in the accompanying drawings. Thetechnology is capable of other embodiments and of being practiced andearned out in various ways. Also, it is to be understood that thephraseology and terminology employed are for the purpose of descriptionand should not be regarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The technology is illustrated and described herein with reference to thevarious drawings, in which like reference numbers denote like methodsteps and/or system components, respectively, and in which:

FIG. 1 is a schematic diagram of a stand-alone battery charger andconditioner, according to an embodiment of this technology;illustrating, in particular, the control interface, battery conditionercontrols and data logging equipment, battery conditioner, and shown inuse with a high voltage battery and its battery management system;

FIG. 2 is a schematic wiring diagram of a stand-alone battery chargerand conditioner, according to an embodiment of this technology,illustrating, in particular, the power supply and discharge unit, 12Vpower supply, controller, intermediate connector, accessible fuse for12V, emergency shut-off, input voltage connector, controller areanetwork bus, and battery access cables;

FIG. 3 is a diagram illustrating the battery capacity verificationprocedure with a plot of the state of charge of the battery over time,according to an embodiment of this technology, illustrating, inparticular, the starting state of charge, first discharge, charge, andsecond discharge; and

FIG. 4 is a flowchart diagram illustrating a method, according to anembodiment of the technology, for accessing diagnostics of a batterybeing tested, determining whether a quick charge is desired or a stateof charge level is desired, discharging the battery, charging thebattery, and displaying the battery conditioner's cycle data.

DETAILED DESCRIPTION OF THE INVENTION

Before describing the disclosed embodiments of the technology in detail,it is to be understood that the technology is not limited in itsapplication to the details of the particular arrangement shown heresince the technology is capable of other embodiments. Also, theterminology used herein is for the purpose of description and not oflimitation.

In various exemplary embodiments, the technology described hereinprovides a portable, stand-alone intelligent battery charger andintelligent conditioner for use with, a high-voltage battery, such asthose used in hybrid automotive vehicles. Additionally, in variousexemplary embodiments, this technology provides a system and method forvalidating the capacity of a high voltage battery. Other comparable usesare also contemplated herein, as will be obvious to those of ordinaryskill in the art.

Referring now to FIG. 1, a stand-alone battery charger and conditionersystem 100 is shown according to an embodiment of this technology. Thestand-alone battery charger and conditioner system 100 is used to chargeor discharge a battery, such as one used in a hybrid or electricvehicle, to a desired level.

The stand-alone battery charger and conditioner system 100 includes ahigh voltage source 140. The system 100 design is flexible such that thehigh voltage source 140 may be 110V 60 Hz or 240V 50 Hz. Additionally,the high voltage source 140 is automatically detected by the system 100.For the 12 Volt source 112, this automatic detection is performed bystandard electronics, known in the art, at the transformer level. Forthe high voltage source 140, the benefit of plugging into a highervoltage provides a higher current capability. For example, one obtainsmore power from 240 Volts at 10 Amps than from 120 Volts at 10 Amps.Thus, the quick charge option is even better.

The stand-alone battery charger and conditioner system 100 includes acontrol interface 110. The stand-alone battery charger and conditionersystem 100 includes a battery conditioner 130 and battery conditionercontrols 120. The control interface 110 provides a 12V source 112 to thebattery conditioner 130 and battery conditioner controls 120.Additionally, the control interface 110 provides digital switches 114,an analog knob 116, and a momentary switch 118. Each of these is aphysical input with which a user makes a decision. Alternative controlsmethods are available. In this example, however, the digital switch 114is a switch to turn on or off certain portions of the stand-alonebattery charger and conditioner system 100. The analog know 116 is aknob with which to dial in parameters. The momentary switch 118 performssimilar functionality as the digital switch 114 but using a momentaryswitch. The control interface 110 is electrically coupled with a coupler122 to the battery conditioner controls 120. The battery conditionercontrols 120 are electrically coupled with a coupler 132 to the batteryconditioner 130.

The battery conditioner controls 120 also include data logging equipment124. The data logging equipment 124 is, while in use with a high voltagebattery, electrically coupled with coupler 126 to a high voltage battery150 and its battery management system 152.

The battery conditioner 130 further includes power electronics 134including a power supply and discharge unit. The power supply anddischarge unit are configured to discharge and/or charge a high voltagebattery 150 to a desired state of charge. The power electronics 134 are,when in use with a high voltage battery 150, electrically coupled withcouplers 136, 138 to the positive and negative leads 154, 156 of thehigh voltage battery 150.

The stand-alone battery charger and conditioner system 100 is portableand utilizes the battery conditioner 130, the control interface 110, thelow voltage source 112, the data logging equipment 124, and powerelectronics 134 as a stand-alone system for ease of use.

The battery management system 152 of the high voltage battery 150provides automatic adaptation to various types and/or manufacturers ofhigh voltage battery packs. The battery management system 152 providesthe diagnostic information over the CAN line 126 to the conditionercontrols 120. The conditioner controls 120 then recognize or reject thebattery pack 150, depending on whether the charger has been programmedfor use with, that battery 150. The battery utilizes either primary orsecondary targeting (i.e., nominal or exact state of charge (SOC)). TheSOC from the battery management system 152 is treated as the primarySOC. The secondary SOC is the exact SOC, determined by capacity. If thebattery 150 has been manufactured properly, by the end of the capacityverification, the SOC from the battery management system 152 shouldmatch the exact capacity. The stand-alone battery charger andconditioner system 100 allows a user to select a desired state of chargefor testing. This battery charger and conditioner system 100 is notlimited to the nominal capacity (as utilized by the battery managementsystem 152) but also can provide a real capacity determination.Additionally, the battery charger and conditioner system 100 determinesthe general and/or specific health of the high voltage battery. Thesystems known in the art require a portable computer device, or thelike, used in combination with the battery charger to provide a state ofcharge to a battery. This battery charger and conditioner system 100does not require a portable computer device, or the like.

The stand-alone battery charger and conditioner system 100 is useful invehicle development and engineering. The system 100 allows a pointsetting of an exact state of charge prior to a test and provides thestate of charge after a test. Additionally, the stand-alone batterycharger and conditioner system 100 is used in service. The system 100 isused to revive a discharged battery (for example, a battery to weak tocrank the vehicle). The system 100 is used to determine if a highvoltage battery is in “good health,” such as validating whether thebattery is healthy enough to be used, validating (or denying) warrantyclaims, servicing a battery that has been in storage for an extendedperiod of time, and displaying or printing battery warranty data.

Referring now to FIG. 2, a schematic wiring diagram 200 of a stand-alonebattery charger and conditioner 100 of FIG. 1, according to one exampleembodiment of this technology, is shown. Cables 210, 212 provideelectrical connectivity between a high voltage battery (not shown) andthe power supply and discharge unit 220. The stand-alone battery chargerand conditioner 100 provides a 12V power supply 230 and includes anaccessible fuse for 12V 250. The stand-alone battery charger andconditioner 100 is shown with, a MPC 555 controller 240; however, asknown in the art other suitable controllers may be used in alternativeembodiments.

Referring now to FIG. 3, a diagram 300 illustrating the battery capacityverification procedure is shown. The diagram 300 illustrates the stateof charge of the battery over time, illustrating in particular, thestarting state of charge, first discharge, charge, second discharge, andwait periods. The conditioner is not limited to this process. This is,however, an exemplary embodiment.

Referring now to FIG. 4, a flowchart diagram 400 illustrating variousmethods for the intelligent charging and conditioning of a high voltagepropulsion battery to a desired state of charge is shown. One method forthe intelligent charging and conditioning of a high voltage propulsionbattery includes utilizing a high voltage source, attaching a batteryconditioner to a high voltage battery 410, the battery conditioner beingpowered by the high voltage source and being configured to electricallyattach to a high voltage battery and assess a plurality of batterydiagnostics, powering on the battery conditioner and applying 12V power412, utilizing a control interface, the control interface being poweredby the high voltage source, utilizing a low voltage source, the lowvoltage source being located within the control interface and providingpower to a battery conditioner control and a data logging device,utilizing a power supply mid discharge unit, the power supply anddischarge unit being located within the battery conditioner and beingconfigured to discharge and charge a high voltage battery to a desiredstate of charge, using the battery conditioner to assess the diagnosticsof the battery 414, displaying a plurality of internal diagnostics ofthe high voltage battery 416, and determining whether a user desires aquick charge of the high voltage battery 428.

Assuming that a user opts for a quick charge to the high voltagebattery, the method next includes determining 432 a target state ofcharge, charging 436 or discharging the high voltage battery until thetarget state of charge has been reached, checking 424, with the batteryconditioner, for a rational relationship between the target state ofcharge and a battery management system located within the high voltagebattery, and displaying 426 the battery conditioner's cycle data.

Assuming that a user opts to not select a quick charge to the highvoltage battery, the method next includes determining 430 whether toseek a target state of charge to cycle the high voltage battery. Uponselecting, in step 430, to seek a target state of charge, the methodnext includes determining 434, by the battery conditioner, the targetstate of charge and then selecting 438 whether the state of chargedesired is to be nominal or exact. Upon selecting, in step 438, an exactstate of charge, the method next includes discharging 440 the highvoltage battery to a lower voltage threshold, charging 442 tire highvoltage battery to an upper voltage threshold, discharging 444 the highvoltage battery to the target state of charge determined by the batteryconditioner, checking 424, with the battery conditioner, for a rationalrelationship between the target state of charge and a battery managementsystem located within the high voltage, battery, and displaying 426 thebattery conditioner's cycle data.

However, upon selecting, in step 438, a nominal state of charge, themethod next includes discharging 446 the high voltage battery to a lowervoltage threshold, charging 448 the high voltage battery to a state ofcharge indicated by the battery management system of the high voltagebattery, checking 424, with the battery conditioner, for a rationalrelationship between the target state of charge and a battery managementsystem located within the high voltage battery, and displaying 426 thebattery conditioner's cycle data.

If, however, in step 430, a user selects to cycle the high voltagebattery, the method next, includes discharging 418 the high voltagebattery to a lower voltage threshold, charging 420 the high voltagebattery to an upper voltage threshold, repeating the discharging andcharging processes three, times, for example, discharging 422 the highvoltage battery to a target state of charge determined by the batteryconditioner, checking 424, with the battery conditioner, for a rationalrelationship between the target state of charge and the batterymanagement system located within the high voltage battery, anddisplaying 426 the battery conditioner's cycle data.

Although this technology has been illustrated and described herein withreference to preferred embodiments and specific examples thereof, itwill be readily apparent to those of ordinary skill in the art thatother embodiments and examples can perform similar functions and/orachieve like results. All such equivalent embodiments and examples arewithin the spirit and scope of the technology and are intended to becovered by the following claims.

1. A system for the intelligent charging and conditioning of a highvoltage battery to a desired state of charge, the system comprising: ahigh voltage source; a battery conditioner, the battery conditionerbeing powered by the high voltage source and being configured toelectrically attach to a high voltage battery and perform a plurality ofbattery diagnostics, the battery conditioner further being operable toautomatically determine whether the high voltage battery is compatiblewith the intelligent charging and conditioning system; a controlinterface, the control interface being powered by the high voltagesource; a low voltage source; the low voltage source being locatedwithin the control interface and providing power to a batteryconditioner control, and a data logging device; and a power supply anddischarge unit, the power supply and discharge unit being located withinthe battery conditioner and being configured to discharge and charge thehigh voltage battery to a desired state of charge.
 2. The system for theintelligent charging and conditioning of a high voltage battery to adesired state of charge of claim 1, wherein the system is coupled to thehigh voltage battery to charge the high voltage battery to a desiredstate of charge.
 3. The system for the intelligent charging andconditioning of a high voltage battery to a desired state of charge ofclaim 1, wherein when the system is coupled to a high voltage batterylocated in a hybrid or electric vehicle that is depleted to a chargelevel at which it is unable to start the vehicle, the batteryconditioner is operable to charge the high voltage battery to a state ofcharge necessary to start the vehicle.
 4. The system for the intelligentcharging and conditioning of a high voltage battery to a desired stateof charge of claim 1, further comprising: a user interface, the userinterface comprising a display screen and being configured to provide auser with battery diagnostic data, battery conditioner data, and stateof charge data, and wherein the data is displayed to the user prior,during, and after battery conditioning.
 5. The system for theintelligent charging and conditioning of a high voltage battery to adesired state of charge of claim 4, wherein the user interface furthercomprises: an audible warning system, wherein the audible warning systeminforms a user of a critical battery status.
 6. The system forteintelligent charging and conditioning of a high voltage battery to adesired state of charge of claim 1, wherein the battery conditioner, thecontrol interface, the low voltage source, the data logging device, andthe power supply and discharge unit comprise a portable, stand-alonesystem.
 7. The system for the intelligent charging and conditioning of ahigh voltage battery to a desired state of charge of claim 1, furthercomprising updatable logic configured to: use controller area network(CAN) parameters and/or diagnostic parameters for battery conditioningalgorithms.
 8. The system for the intelligent charging and conditioningof a high voltage battery to a desired state of charge of claim 1,wherein the data logging device records high voltage battery data prior,during, and after battery conditioning for engineering analysis andprints a paper receipt of logged activities.
 9. The system for theintelligent charging and conditioning of a high voltage battery to adesired state of charge of claim 7, wherein the updatable logic isfurther configured to: charge the high voltage battery to apredetermined nominal state of charge.
 10. The system for theintelligent charging and conditioning of a high voltage battery to adesired state of charge of claim 7, wherein the updatable logic isfurther configured to: charge the high voltage battery to apredetermined exact state of charge.
 11. The system forte intelligentcharging and conditioning of a high voltage battery to a desired stateof charge of claim 1, wherein if the high voltage battery is determinedto be incompatible with the battery conditioner, the battery conditioneris further operable to reject charging the high voltage battery.
 12. Thesystem for the intelligent charging and conditioning of a high voltagebattery to a desired state of charge of claim 1, wherein the batteryconditioner is further operable, if the high voltage battery iscompatible with the battery conditioner, to set a target state of chargebased on a known exact capacity of the high voltage battery.
 13. Thesystem for the intelligent charging and conditioning of a high voltagebattery to a desired state of charge of claim 1, wherein the batteryconditioner is further operable to quick charge the high voltage batteryby: determining a target state of charge; charging or discharging thehigh voltage battery until the target state of charge has been reached;and checking for a rational relationship between the target state ofcharge as determined by the battery conditioner and a state of chargeretrieved from a battery management system located within the highvoltage battery.
 14. The system for the intelligent charging andconditioning of a high voltage battery to a desired state of charge ofclaim 1, wherein the battery conditioner is further operable to chargethe high voltage battery to a target state of charge by: discharging thehigh voltage battery to a lower voltage threshold; charging the highvoltage battery to an upper voltage threshold; discharging the highvoltage battery to the target state of charge as determined by thebattery conditioner; and checking for a rational relationship betweenthe target state of charge as determined by the battery conditioner anda state of charge retrieved from a battery management system locatedwithin the high voltage battery.